SYSTEMS AND METHODS OF CONSTRUCTION

Abstract

Provided is a method of construction employing a prefabricated wall system. The method provides for assembly of the wall system on the construction site. Embodiments of the wall system and the methods of use thereof are provided for.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. national phase application under 35 U.S.C. 371 of International Application No. PCT/US2022/024117, filed on Apr. 8, 2022, which claims the benefit of U.S. Provisional Application No. 63/172,576, filed Apr. 8, 2021, which are incorporated by reference herein in their entirety for all purposes.

FIELD OF THE INVENTION

The present disclosure relates to methods of construction, and more particularly in the use of modular wall systems, ceiling systems, and floor systems in methods of construction.

BACKGROUND OF THE INVENTION

Current construction methods can be unpredictable. Under current methods a frame of a building is erected, followed by independent teams of plumbers, electricians, etc., who each modify the frame of the building. Each independent modification compounds the chances of human error and increases building costs and time.

We have invented a method utilizing a new form of construction to optimize speed, efficiency, and cost in construction framing. The disclosed wall system can be created within the confines of a manufacturing facility in order to keep very tight tolerances and decrease mistakes. The wall system ranges from a structurally insulated panel (SIP) to a wall with finished interior and exterior walls with conduit(s) and/or utilities pre-installed within the wall.

SUMMARY OF THE INVENTION

In one aspect, the present technology features a fabricated wall system containing one or more prefabricated structurally insulated panels. The structurally insulated panels contain an exterior wall, an interior wall, one or more locking devices, and insulation between the exterior wall and the interior wall.

In some embodiments, the insulation has one or more voids. In preferred embodiments, the one or more voids are partially filled with utility elements, e.g., plumbing, HVAC ducting, electrical conduit, A/V wiring, etc.

In some embodiments, the utility elements contain plumbing. In other embodiments, the utility elements contain HVAC ducting. In still other embodiments, utility elements contain electrical conduit. In yet other embodiments, the utility elements contain A/V wiring.

In some embodiments, the interior wall comprises one or more voids. In some embodiments, the voids/conduits are shaped, rectangular or cylindrical (e.g., as required and centered at approximately 1′3″ and/or 3′6″ from an edge of the interior wall). The appropriate voids will be placed where desired and/or regionally acceptable to code.

In some embodiments, the exterior wall and/or interior wall comprise oriented strand board, and or plywood.

In some embodiments, the insulation comprises extruded graphite polystyrene.

In some embodiments, the exterior wall contacts siding or roofing.

In some embodiments, the interior wall contacts drywall, plaster, concrete, metal sheets or wallpaper.

In some embodiments, panels are “weathered in” by using a composite serving as flashing applied there between.

In some embodiments, two or more prefabricated structurally insulated panels (SIPs) are affixed to each other using a locking mechanism.

In some embodiments, one or more prefabricated structurally insulated panels comprise at least one or more properties chosen from the group of: fire resistant, anti-fungal, insecticidal, non-slip, anti-UV (ultra violet) light, water resistant, or a combination of such properties.

In some embodiments, one or more prefabricated structurally insulated panels are affixed to siding or roofing using a locking mechanism.

In another aspect, the present technology features a method of construction using the steps of:

• • a) providing a prefabricated wall system as described in the present embodiments;
  • b) aligning the prefabricated wall system with a building foundation or flooring; and
  • c) locking the prefabricated wall system together and to the foundation or flooring.

In some embodiments, the method also involves:

• • d) aligning the prefabricated wall system with a prefabricated ceiling or roof; and
  • e) locking the wall system to the ceiling or roof.

In further embodiments, the method also involves:

• • f) aligning the prefabricated wall system with a prefabricated subfloor or finished floor or roof; and
  • g) locking the wall system to the subfloor or roof or finished floor.

DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-section of an embodiment of a structurally insulated panel (SIP) suitable for the presently disclosed wall system 100. In this embodiment the SIP comprises 1) a medium density phenolic-impregnated polymer-modified air/vapor barrier 102 on 2) an oriented strand board (OSB) or plywood outer wall 104, 3) insulation comprising extruded graphite polystyrene (GPS) 106 with embedded conduit for HVAC 108, plumbing 110, and electrical utilities 112, and 4) an inner OSB 114 or plywood wall with 5) finish grade interior 116 (e.g., drywall or plaster).

FIG. 2 illustrates a cross-section of an embodiment of a SIP suitable for the presently disclosed wall system 200. In this embodiment the SIP comprises 1) siding 218 on 2) a medium density phenolic-impregnated polymer-modified air/vapor barrier 202 on 3) an OSB or plywood outer wall 214, 4) insulation comprising extruded graphite polystyrene (GPS) 216 with embedded conduit(s) for HVAC 208, plumbing 210, A/V, and electrical utilities 212, and 5) an inner OSB 204 or plywood wall with 6) finish grade interior 206 (e.g., drywall or plaster or other finishing materials).

FIG. 3 illustrates a wall system 300 comprising multiple SIPs with multiple layers of cutaway. This embodiment features SIPs with light switches 302 and power outlets 304 embedded in the SIP and finish grade interior, an interior wall 306 to which the finish grade interior 308 is affixed, an exterior wall 310, insulation 312 between the interior and exterior walls, locking mechanisms 314 (e.g., type A) in the header and side board, and electrical writing 314.

FIG. 4 illustrates an embodiment of a wall system 400 comprising multiple SIPs in which the wall system 400 makes up the exterior of the building 402, and a wall, which is an interior wall 404, attaches (optionally to a stud) to the wall system 400 making up the exterior of the building. This embodiment features SIPs with studs to form a door frame 410 and a window frame 412. In this embodiment, other described features are also present, including graphite polystyrene (GPS) insulation 408, an air/vapor barrier, OSB/plywood interior and exterior walls 402, 404, plaster/drywall interior finish, exterior siding, A/V (e.g., audio, visual, Cat 5 cable), electrical wiring/conduit, HVAC conduit, plumbing conduit, and a footer plate with locking mechanisms 406A-406B.

FIG. 5 illustrates a wall system 500 comprising multiple SIPs with multiple layers of cutaway. The embodiment also features an air/vapor barrier 506 and an insulation 508 between interior 504 and exterior walls 502, and side boards 510 and a header 507 with locking mechanisms 506A-506B (e.g., types A and B).

FIG. 6 illustrates a wall system 600 comprising multiple SIPs with multiple layers of cutaway. This embodiment features siding affixed to an air/vapor barrier 612 which is affixed to an exterior wall. The embodiment also features insulation 608 between the exterior wall 602 and an interior wall 604, and a header 607, a footer 610, and side boards 605 with locking mechanisms (types A and B) 606A-606B.

FIGS. 7 and 8 illustrate an embodiment of type A and type B locking mechanisms made from an exterior-threaded cylinder, and an interior-threaded receiver.

FIG. 9 illustrates a cross-section of an embodiment of a SIP of the present technology. This embodiment features siding 905 affixed to building wrap affixed to an exterior wall 902. The embodiment also features insulation between the exterior wall 902 and an interior wall 904. The exterior and interior walls also contact a footer and a header with locking mechanisms (types A and B). Finish grade interior 909 is also affixed to the interior wall 904. In this embodiment, other described features are also present, including graphite polystyrene (GPS) insulation 908, an air/vapor barrier 924, OSB/plywood interior and exterior walls 902, 904, plaster/drywall interior finish 926, exterior wall siding 928, A/V (e.g., audio, visual, Cat 5 cable) 912, electrical wiring/conduit 914, HVAC conduit 918, plumbing conduit 916, and a footer plate 920 with locking mechanisms.

FIGS. 10 and 11 illustrate embodiments of a wall systems 1000, 1100 utilizing SIPs in which an exterior or interior wall of a SIP has gel or liquid flashing 1002, 1102 or composite applied (optionally in a channel in the wall) to seal two sections of SIP in a wall system. In one wall system 1000, 1100, the exterior wall 1004, 1104 and interior wall 1006, 1106 can be coupled with a tongue and groove coupling 1008, 1108. The wall system 1100 can use an alternative coupling at the flashing 1102.

FIG. 12 illustrates a wall system 1200 connecting to a flooring and/or ceiling/roof. In this embodiment, the type A locking mechanism is embedded in the face of the wall system, and the type B mechanism is embedded in the edge of the flooring and/or ceiling/roof.

DETAILED DESCRIPTION

Wall systems represent a method of construction in which some or all of the framing, insulation, utilities, siding, etc. are completed off-site and transported to the construction site. The wall system can then be attached to the foundation and/or structural support of the unfinished building. Wall systems may comprise structurally insulated panels (SIPs) equipped with a locking mechanism to quickly connect the wall to the unfinished building on-site. SIPs may also be used in constructing a floor and/or roof, which are both including in the term “wall system.” This method of construction allows for fewer modifications and less chance for human error on-site, as well as simple modifications that can be made at the construction site by merely replacing portions of the wall system as desired.

Structurally Insulated Panels (SIPs)

Structurally insulated panels are pre-fabricated portions of a wall system with an exterior wall, an interior wall, and an optional layer of insulation in between (see, e.g., FIG. 1). A SIP may be made of any construction material known in the art suitable for use in a wall. For example, wood products in all various grades such as OSB, Plywood, concrete, and metal, etc. A preferred material is oriented strand board (OSB). SIPs have the advantage of versatility in shape and size, including width, height, and thickness, being suitable to any shape and size used in the art. In preferred embodiments SIPs are between 4 feet and 8 feet in a first dimension (e.g., between 4 and 6 feet, or between 6 and 8 feet), and between 8 and 24 feet in a second dimension (e.g., between 8 and 12 feet, between 12 and 16 feet, between 16 and 20 feet, or between 20 and 24 feet). Finished exterior and interior elements may be affixed to SIPs off-site, including, but not limited to, siding, plaster, drywall, paint, wallpaper, shingles, tile, wood flooring, light fixtures, power outlets, etc. (see, e.g., FIGS. 2 and 3). Insulation used in SIPs may be any used in the art and may be installed and/or modified off-site. In a preferred embodiment the insulation is graphite polystyrene (GPS).

SIPs may optionally comprise studs as needed for stability or to act as an anchor for a wall extending into the interior of a room (see, e.g., FIG. 4). For example, a SIP may have a stud equipped with locking mechanisms to which another SIP and/or traditionally framed wall may attach. Additionally, SIPs may contain king studs, jack studs, and cripple studs for additional support for windows, skylights, doors, doorways, etc. (see, e.g., FIG. 5).

SIPs may also contain a footer and/or a header and side boards (see, e.g., FIG. 6). A footer/header and side boards comprise any material compatible with SIPs described herein and act as anchors to add a ceiling/roof to the header, to add the SIP to the flooring/foundation by way of the footer, and/or to adjoin multiple sections of SIP together to form the wall system. Headers/footers and side boards include the necessary locking mechanisms as described herein to join the wall system together, or to affix the wall system to a footer/foundation, and/or to a roof/ceiling.

Aligned and locked SIPs form the wall system which may be sealed using methods known in the art, including but not limited to a liquid flashing or sealing tape. Adjoining exterior and interior walls may be sealed at the gaps between SIPs, or the entire wall system may be sealed, as in a building wrap (see, e.g., FIG. 7). Alternatively, the interior finish may act to cover the gaps between SIPs, as in wallpaper, drywall, plaster, etc.

Insulations

Wall systems may use any insulation commonly used in methods of construction, including but not limited to, sheets, foam board, loose-fill, blow-in, and sprayed insulation. The insulation may be installed and modified in a SIP at the point of manufacture or use. The material used in the insulation may be any known in the art, including but not limited to, fiberglass, cellulose, foam, mineral wool, natural fibers, denim, and polystyrenes (e.g., graphite polystyrene). In a preferred embodiment the insulation contains graphite polystyrene. The presently described wall system may be paired with the insulation appropriate for the application. In preferred embodiments, insulation may be rated based on an RSI-value (m²·K/W) of between 0.1 and 10, e.g., between 0.1 and 0.2, between 0.2 and 0.3, between 0.3 and 0.4, between 0.4 and 0.5, between, 0.5 and 0.6, between 0.6 and 0.7, between 0.7 and 0.8, between 0.8 and 0.9, between 0.9 and 1.0, between 1.0 and 1.5, between 1.5 and 2.0, between 2.0 and 2.5, between 2.5 and 3.0, between 3.0 and 3.5, between 3.5 and 4.0, between 4.0 and 4.5, between 4.5 and 5.0, between 5.0 and 5.5, between 5.5 and 6.0, between 6.0 and 7.5, between 7.5 and 8.0, between 8.0 and 8.5, between 8.5 and 9.0, between 9.0 and 9.5, or between 9.5 and 10 RSI. An important modification of the insulation is cutting holes or voids into the insulation for heating, ventilating, and air conditioning (HVAC), air barriers, vapor barriers, electrical conduit and wiring, plumbing, etc.

Air and Vapor Barriers

Air and moisture control are important features of a wall system. Air barriers control the flow of air to prevent heated or cooled air to escape, or to prevent low quality air in to the building. Vapor barriers control the flow of moisture to discourage the growth of mold or fungi in the wall, and to control the humidity inside the building. Because a significant amount of moisture can be in the air, air barriers and vapor barriers may, at times, overlap in function and/or structure. Depending on the conditions under which a wall system is used (e.g., local climate), the design and use of one or more air and/or vapor barriers (e.g., location of the barrier in the wall system, permeability of the barrier, etc.) may change.

Structurally insulated panels may contain one or more air and/or vapor barriers by, for instance, removing a layer of insulation, leaving a gap between the outer wall and siding (e.g., brick, panel, wood, composite, or vinyl siding), leaving a gap between the inner wall and interior finish (e.g., drywall, treated wall), or by leaving a portion of the gap between the exterior wall and the interior wall of the SIP empty. Air and/or vapor barriers may be sealed using Class I Vapor Retarder (vapor impermeable, 0.1 perm or less), Class II Vapor Retarder (vapor semi-impermeable, between 0.1 and 1.0 perm), or Class III Vapor Retarder (vapor semi-permeable, between 1.0 and 10 perms), or may comprise a gap with weep holes in adjoining layers, as in, e.g., a water resistive barrier (WRB), or a drainage plane.

A properly sealed SIP may create a vapor barrier with a permeability rating of less than 0.1 perm, or a code-compliant air barrier with a permeability rating between 0.1 and 1.0 perm, e.g., between 0.1 and 0.2, between 0.2 and 0.3, between 0.3 and 0.4, between 0.4 and 0.5, between 0.5 and 0.6, between 0.6 and 0.7, between 0.7 and 0.8, between 0.8 and 0.9, or between 0.9 and 1.0 perm. The wall systems disclosed may use any of the air and/or vapor barrier materials used in the art, including but not limited to, building papers (e.g., asphalt-backed kraft paper, heavy asphalt-impregnated papers, phenolic-impregnated papers, etc.), paints (e.g., vapor-retarding paints, oil-based paints, latex-based paints, etc.), elastomeric membranes and coatings, vinyl wall coverings, extruded polystyrene, plywood, OSB, unfaced expanded polystyrene, and fiber-faced isocyanurate or polyisocyanurate. Other properties of air and/or vapor barriers known in the art may be combined with embodiments of the present disclosure, e.g., density, polymer-modification, and impregnation. A preferred embodiment uses a medium density, phenolic-impregnated, polymer modified air and/or vapor barrier. By installing an air and/or vapor barrier in the SIP, additional air and/or vapor barriers may not be required in the building construction, either in the wall, or elsewhere.

HVAC

Heating, ventilation and air conditioning (HVAC) elements and/or systems may be installed in the space between the exterior and interior walls of a wall system in the fabrication stage, or after installation at the construction site. Spaces in the insulation may be left during the installation of the insulation, or may be removed after installing the insulation. The present disclosure is not limiting to the design or materials used in HVAC, and is suitable for any known in the art. For example, split systems, single-unit systems, heat pumps, ductless mini-split systems, packaged heating, and air systems.

Electrical

Wall systems may be fabricated with electrical conduit and/or wiring. Alternatively, or in addition to wall systems fabricated with electrical conduit and/or wiring, electrical conduit and/or wiring may be installed on-site in or to wall system(s). Any electrical conduit in the art is amenable to the presently disclosed wall system, including but not limited to all internal wall installations covered within the National Electric Code (NEC) and other standard electrical codes or regulations. This includes, romex at all variable sizes, SIMpull, stranded and solid wire of all color variations, cable, A/V wire, data cabling (e.g., Cat 5 cable), security wiring, speaker wire of all gauges, etc. In preferred embodiments, insulation will be removed to install electrical conduit and/or wiring, or the insulation will be installed with spaces for the electrical conduit and/or wiring to be installed. Alternatively, the conduit and/or wiring may be put in place as the insulation is installed around it.

Plumbing

Wall systems may be fabricated with plumbing, or plumbing may be installed on-site. Any plumbing in the art is amenable to the presently disclosed wall system. This includes but is not limited to all internal wall installations covered within the National Standard Plumbing Code (NSPC) and other standard plumbing codes or regulations. Examples include cast iron, cross-linked polyethylene (PEX, XPE, XLPE), polybutylene (PB), copper, steel, poly vinyl chloride (PVC), etc. In preferred embodiments, insulation will be removed to install plumbing, or the insulation will be installed with spaces for the plumbing to be installed. Alternatively, the plumbing may be put in place as the insulation is installed around it.

Wall Materials

Wall systems of the present disclosure may have an interior and exterior wall made from the same, or different wall materials. In a preferred embodiment the interior and/or exterior wall contains oriented strand board. Alternatively, the wall systems disclosed herein may use any wall material known in the art (e.g., wood of all grades such as OSB/Plywood, metal such as steel, concrete, stone, brick, etc.). The wall materials may have one or more materials (e.g., layers, coatings) applied with advantageous properties including, but not limited to, fire resistant, anti-fungal, insecticide, and water resistant coatings.

In a preferred embodiment of the disclosed wall system, the wall material is made of an engineered wood (e.g., plywood, oriented strand board, densified wood, fireboard, particle board, laminated woods, etc.). In a more preferred embodiment the engineered wood is oriented strand board.

Advantageous Materials

The wall system presently disclosed may have materials (e.g., coatings, layers) with advantageous properties. The materials described herein may have one or more beneficial properties suitable to the use of the wall system. As non-limiting examples, the materials may have fire resistant, anti-fungal, insecticidal, non-slip, anti-UV (ultra violet) light, or water resistant properties, or some combination of such properties. Other coatings known in the art may also be applied to the present embodiments.

Fire Resistant

Fire resistance may be integrated into the wall systems of the present disclosure. Fire resistance may be through a fire resistant or intumescent materials (e.g., paint, coating, application, etc.). Fire resistant materials include those that act by disrupting the free-radical reactions of fire, those that release water or non-oxygen gases when heated, or those that form a “char” layer of material to protect the flammable materials. Fire resistant materials include, but are not limited to, halogenated fire resistant materials (e.g., tris(2-chloroisopropyl) phosphate), non-halogenated materials (e.g., diethyl hydroxylmethyl phosphonate), non-reactive organic phosphorous (e.g., butyl diphenyl phosphate, dibutyl phenyl phosphate, triphenyl phosphate), reactive organic phosphorous (e.g., diethyl hydroxylmethyl phosphonate), non-halogenated organic phosphorous (e.g., dialkyl hydroxyalkanephosphonate) and inorganic fire resistant materials (e.g., magnesium salts). Such fire resistant materials may be applied before or after the assembly of the SIP or after assembly of the wall. The thickness of the materials, method of application, and other features of the fire resistant materials are commensurate with the best practices of the available art.

Anti-Fungal

Anti-fungal properties are compatible with the wall systems of the present disclosure. Anti-fungal properties may be achieved through an anti-fungal material (e.g., coating, layer) applied before or after assembly of the wall system. Anti-fungal materials include, but are not limited to, carbamates (e.g., 3-iodo-2-propynyl N-butyl carbamate), 14a-demethylase inhibitors (e.g., propiconazole), and benzimidazoles (e.g., carbendazim). Such anti-fungal materials may be applied before or after the assembly of the SIP or after assembly of the wall. The thickness of the anti-fungal material, method of application, and other features of the anti-fungal materials are commensurate with the best practices of the available art.

Insecticide

Insecticidal properties are also compatible with the wall systems of the present disclosure. Insecticidal properties may be achieved through an insecticidal material (e.g., coating, layer) applied before or after assembly of the wall system. Examples of such materials include, but are not limited to, pyrethyroids (e.g., permethrin, d-trans-allethrin, resmethrin, tetramethrin, sumithrin), acetylcholinesterase inhibitors (e.g., parathion, diazinon, malathion), cyclodiene-based organochlorines (e.g., heptachlor, aldrin, dieldrin, chlordane, endrin), DEET and DDT. Such insecticidal materials may be applied before or after the assembly of the SIP or after assembly of the wall. The thickness of the insecticidal material, method of application, and other features of the insecticidal materials are commensurate with the best practices of the available art.

Water Resistant

Water resistant properties are also compatible with the wall systems of the present disclosure. Water resistant properties may be achieved through a water resistant material (e.g., coating, layer) applied before or after assembly of the wall system. Examples of such materials include, but are not limited to, polymers (e.g., polyvinyl chloride, polycarbonate, polyethylene, polypropylenes, polyacrylonitrile, polystyrene, acrylonitrile butylene styrene, acrylic polymers) and copolymers. Such water resistant materials may be applied before, during, or after the assembly of the SIP(s) or after assembly of the wall. The thickness of the water resistant material, method of application, and other features of the water resistant materials are commensurate with the best practices of the available art.

Other

Other advantageous materials (e.g., coatings, layers) include preservatives, non-slip, and UV reflective materials. Non-limiting examples of preservatives include chromated copper arsenate, borates, azoles, triazoles, alkaline copper, alkaline copper quaternary salts, alkaline copper zinc arsenates, tebuconzaole, quaternary ammonium compounds, isothiazolones, and carbamates.

Siding

The exterior wall of the wall system herein disclosed can be equipped with siding at the point of manufacture or after. Any siding known in the art may be used, including, but not limited to, UV reflective materials, wood siding, shingles, drop siding, stone siding, vinyl siding, PVC siding, metal siding, panels, plastic siding, or any other natural or man-made product intended in the use of siding. In a preferred embodiment, the siding is installed at the point of manufacture to further reduce the on-site construction time.

Interior Utilities

The interior wall of the wall system herein disclosed may have finished interior utilities (e.g., power outlets, light switches, light bulbs, light strips, speakers, internet or Ethernet cables, monitors, fans, etc.) installed at the point of manufacture or after installing the wall system. Alternatively the wiring and plumbing may be installed during manufacture and certain other of the finished interior utilities installed afterward (e.g., sinks, showers, toilets, bathtubs, etc.). The location of power outlets and light switches is not restricted to any height or the presence of a stud. In preferred embodiments, the power outlets are installed in standard locations (e.g., about 1′3″, or other distances depending on the jurisdiction, from the floor) at the point of manufacture. In another preferred embodiment, the light switches are installed in standard locations (e.g., about 3′6″, or other distances depending on the jurisdiction) from the floor.

Interior Walls and Finishing

In some embodiments, the interior wall of the presently disclosed wall system has finishing treatments (e.g., drywall, plaster, wallpaper, paint, tile, wood flooring, or any other man made product intended in the use of interior finishing) installed during manufacture. Alternatively, the interior wall may be finished on-site. Interior walls of adjoining SIPs in the wall system may be sealed with known techniques according to the wall type (e.g., mud and tape for drywall), or by use of a tape (e.g., acrylic tape). The sealing of adjacent interior walls may be accomplished or prepared at the point of fabrication.

One option for finishing completed walls is to use a tape, for example, on the seams and/or joints of the walls and components, for example, mud and tape, composite tape, or an acrylic tape that is commercial or custom grade.

Another option would be to use a gel or liquid composite or flashing applied between joints or edges. Gel or liquid flashing (e.g., silyl-terminated polyethers) may be applied standalone, or after a primer (e.g., based on polymethyl methacrylate). To provide additional integration and connection options, some embodiments can include a channel cut to enable application of composite or flashing directly into the channel, in a portion of the channel, or to fill the channel, during manufacture, or on-site, and further enabling transport with the flashing pre-applied (see, e.g., FIG. 10). This would also have the benefit that no mistakes could happen prior to locking the joints together. The channel could facilitate a tighter fit or bond, and/or allow the composite or flashing to expand and flow to fill any air gap therebetween.

Alternatively, or in addition to the channel embodiment, a gel or liquid composite or flashing could be pre-applied during manufacture or applied on-site, on a cut edge, which “activates” when the other cut edge presses against it and breaks the covering or other mechanism keeping the composite or flashing from causing adhesion or bond (see, e.g., FIGS. 10 and 11). This would be another mechanism for decreasing possible human error, and increasing efficiency and precision in construction.

Locking Mechanisms

A mechanism is provided for affixing the SIP(s) of the wall system to each other and to the flooring or foundation, or roof of the building. For example, in some embodiments the locking mechanism is a simple turn to lock system. The simple mechanism will be embedded into the wall and join where the wall joins with the flooring or ceiling/roof as seen in FIG. 12. In other embodiments the locking mechanism may utilize a hook or a latch, or a keyed mechanism, or use a specialized hex nut and bolt system, or other customized mechanism to help accommodate and account for the various conduit and properties of the wall system.

For example, locking mechanisms may come in two types, e.g., a “type A” and a “type B.” A type A locking mechanism might be, for instance, an externally threaded cylinder (e.g., a screw, bolt, etc.) and may be stationary or moveable (see, e.g., FIG. 8). A type B mechanism may be, for instance, a hex nut or other internally threaded device whose threads are designed to mate with the threads of a type A locking mechanism. Further, the type A locking mechanism may be embedded on the sides of the wall system, as in FIG. 8, or in the face of the wall system, as in FIG. 12, so that the wall system may be joined to the type B mechanism in the edge of a flooring and/or ceiling/roof. Alternatively, the type A and type B placements may be switched, and/or the placements of the mechanisms on the face/edge may be switched (e.g., the locking mechanism may be on the face of the flooring and/or ceiling/roof, and the locking mechanism may be on the edge of the wall system).

Locking mechanisms may be embedded in the SIPs along the sides, top, and/or bottom. Locking mechanisms may be embedded in regular or irregular intervals on the SIP. In preferred embodiments the locking mechanisms are spaced between 1 and 16 inches apart, e.g., between 1 and 2 inches apart, between 2 and 3 inches apart, between 3 and 4 inches apart, between 4 and 5 inches apart, between 5 and 6 inches apart, between 6 and 7 inches apart, between 7 and 8 inches apart, between 8 and 9 inches apart, between 9 and 10 inches apart, between 10 and 11 inches apart, between 11 and 12 inches apart, between 12 and 13 inches apart, between 13 and 14 inches apart, between 14 and 15 inches apart, or between 15 and 16 inches apart.

Flooring

The present wall system technology can also be applied to flooring. The described features can be applied, where appropriate, to the use of the wall system as a floor or subfloor (e.g., insulation, HVAC, plumbing, wiring, etc.). When the wall system is used as flooring or subflooring, further features include interior finish flooring, (including but not limited to, e.g., tile, wood flooring, linoleum, carpet, engineered materials, etc.), natural materials (including but not limited to, e.g., bamboo, cork, concrete, etc.), configurable, movable, and/or heated flooring systems as known in the art, etc. As with other embodiments of the wall system, flooring embodiments can benefit from increased efficiency in construction, decreased construction time on-site, decreased waste, tighter tolerances, and lower cost from being applied and configured with the wall system. Alternatively, a flooring system (e.g., of flooring materials or composition, including materials or flooring known in the art) may be used, and the prefabricated wall systems disclosed herein may be attached to the flooring system described herein or those known in the art. Such flooring systems include flooring, floors, foundations, and subfloors discussed herein and commonly used in the art and/or contemplated in the art.

Ceilings

The present wall system technology can also be applied to ceilings. The advantageous features described herein can be applied, where appropriate, to the use of the wall system as a ceiling (e.g., insulation, HVAC, plumbing, wiring, etc.). When the wall system is used as a ceiling, further features may include skylights, track lighting, raised levels, molding, etc. As with other embodiments of the wall system, ceiling embodiments can benefit from increased efficiency in construction, decreased construction time on-site, decreased waste, tighter tolerances, and lower cost from being applied and configured with the wall system.

Roofing

The present wall system technology can also be applied to roofing. The described features can be applied, where appropriate, to the use of the wall system as a roof (e.g., insulation, air/vapor barriers, etc.). When the wall system is used as a roof, further features include exterior finish, e.g., non-slip layer, shingles, tile, shakes, flashing, eaves, gutters, drains, etc. As with other embodiments of the wall system, the roof embodiment can benefit from increased efficiency in construction, decreased construction time on-site, decreased waste, tighter tolerances, and lower cost from being applied and configured with the wall system.

Tolerances

An important advantage to the wall system presently described is an improvement in the tolerances of construction over an on-site construction method. During construction workers face disadvantages, for example enclosed spaces, hand-held tools, power limitations, poor weather conditions, poor lighting, fatigue, noise, distraction, staffing issues, etc. These often lead to unintended mistakes, physical gaps, or other imprecision in construction. Gaps between sections of framing between interior and exterior sections of wall, between walls and floor, between walls and ceiling, gaps between finished interior (e.g., drywall) and exterior (e.g., siding), misaligned outlets, sockets, pipes, etc., are non-limiting examples of tolerances that the present wall system can improve. Tolerances in construction can be brought down to between 0.05 mm and 2 mm, e.g., between 0.05 mm and 0.1 mm, between 0.1 mm and 0.2 mm, between 0.2 mm and 0.3 mm, between 0.3 mm and 0.4 mm, between 0.4 and 0.5 mm, between 0.5 and 0.6 mm, between 0.6 and 0.7 mm, between 0.7 and 0.8 mm, between 0.8 and 0.9 mm, between 0.9 and 1.0 mm, between 1.0 mm and 1.1 mm, between 1.1 mm and 1.2 mm, between 1.2 mm and 1.3 mm, between 1.3 mm and 1.4 mm, between 1.4 mm and 1.5 mm, between 1.5 mm and 1.6 mm, between 1.6 mm and 1.7 mm, between 1.7 mm and 1.8 mm, between 1.8 mm and 1.9 mm, between 1.9 mm and 2.0 mm, between 0.05 mm and 0.5 mm, between 0.5 mm and 1.0 mm, between 1.0 mm and 1.5 mm, or between 1.5 mm and 2.0 mm.

Efficiency

Another important advantage to the wall system presently described is an improvement in the efficiency of construction over an on-site construction method. During construction workers face disadvantages, for example enclosed spaces, hand-held tools, power limitations, poor weather conditions, poor lighting, fatigue, noise, distraction, staffing issues, etc. These often lead to unintended mistakes, errors, or other issues necessitating re-doing work in construction. Human errors cause delay and waste in construction project. On-site construction times may be reduced by more than 30% by use of the wall system described herein, e.g., reduced by more than 30% 40%, 50%, 60%, 70%, 80%, 90% or 95%.

While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.

Claims

1. A fabricated wall system comprising one or more prefabricated structurally insulated panels, wherein the one or more structurally insulated panels comprise an exterior wall, an interior wall, one or more locking devices, and insulation between the exterior wall and the interior wall.

2. The wall system of claim 1, wherein the insulation comprises one or more voids.

3. The wall system of claim 2, wherein the one or more voids are partially filled with utility elements.

4. The wall system of claim 3, wherein the utility elements comprise one or more of plumbing, HVAC ducting, electrical conduit, or A/V wiring.

5. The wall system of claim 4, wherein the utility elements comprise plumbing.

6. The wall system of claim 4, wherein the utility elements comprise HVAC ducting.

7. The wall system of claim 4, wherein the utility elements comprise electrical conduit.

8. The wall system of claim 4, wherein the utility elements comprise A/V wiring.

9. The wall system of claim 1, wherein the interior wall comprises one or more voids.

10. The wall system of claim 9, wherein the voids are rectangular and centered at approximately 1′3″ and/or 3′6″ from an edge of the interior wall.

11. The wall system of claim 1, wherein the exterior wall and/or interior wall comprise oriented strand board or plywood.

12. The wall system of claim 1, wherein the insulation comprises extruded graphite polystyrene.

13. The wall system of claim 1, wherein the exterior wall contacts siding, roofing, subfloor, or finished flooring.

14. The wall system of claim 1, wherein the interior wall contacts drywall, plaster, or wallpaper.

15. The wall system of claim 1, wherein panels are joined using a composite applied therebetween.

16. The wall system of claim 1, wherein two or more prefabricated structurally insulated panels are affixed to each other using a locking mechanism.

17. The wall system of claim 1, wherein one or more prefabricated structurally insulated panels comprise at least one or more properties chosen from the group of: fire resistant, anti-fungal, insecticidal, non-slip, anti-UV (ultra-violet) light, water resistant, or a combination of such properties.

18. The wall system of claim 13, wherein one or more prefabricated structurally insulated panels are affixed to the siding or roofing using a locking mechanism

19. A method of construction comprising:

providing a prefabricated wall system of;

aligning the prefabricated wall system with a building foundation or flooring; and

locking the prefabricated wall system together and to the foundation or flooring.

20. The method of claim 19, further comprising:

aligning the prefabricated wall system with a roof or ceiling; and

locking the prefabricated wall system to the roof or ceiling.